What is a “communication module”?

A communication module is the card, adapter, or gateway that lets a PLC/RTU/remote I/O talk
to other devices (drives, meters, protection relays, HMI/SCADA, BMS, cloud). Think of it as the
“language port” for your control system.

Avanceon projects (industrial, utilities, buildings, central cooling plants, etc.) commonly use
Schneider, Siemens, and Rockwell platforms—but the types of comms modules are the same
across brands.

Main categories (with Avanceon use-cases)

1) Ethernet communication modules (industrial Ethernet)

What they do: Provide TCP/IP-based networks for high-speed, modern systems.

 Common protocols:
Modbus TCP, PROFINET, EtherNet/IP, BACnet/IP (BMS/HVAC), DNP3-TCP (utilities), IEC
61850 MMS/GOOSE (power).

 Topologies: Star (via switch), Ring (RSTP/MRP), sometimes redundant networks.

 Where Avanceon uses them:

PLC ↔ VFDs/chillers/meters over Modbus TCP; PLC ↔ remote I/O over PROFINET; PLC
↔ SCADA via OPC UA/TCP; BMS integration via BACnet/IP; substations via IEC 61850.

In Schneider tools you’ll see “Ethernet Control Modules” (hardware). Features like I/O
Scanning, Global Data, and IP Forwarding are software functions running on the CPU/NOC.

2) Serial / fieldbus communication modules

What they do: Provide non-Ethernet buses—still very common with devices.

 Modbus RTU (Serial): RS-485 multi-drop to drives, energy meters, chillers. Cheap and
reliable.

 Profibus-DP: Fast cyclic I/O for drives/remote I/O (legacy but still used).

 CANopen: Motion/drives/smart I/O on CAN bus.

 AS-Interface (AS-i): Simple binary sensors/actuators on a two-wire flat cable.

 Others you may see: DeviceNet, HART (via analog/HART cards or gateways).
Where Avanceon uses them:
Brownfield retrofits, long RS-485 runs to meters, Profibus to legacy MCCs, AS-i for dense on/off
I/O.

3) Power & substation comms

 IEC 61850 (MMS/GOOSE/SV): Digital substations, protection relays. Often needs a

compatible Ethernet module or a gateway that translates to PLC protocols.

 DNP3: Water/utilities/RTUs (serial or TCP). Time-stamped events, polling.

4) OPC UA / middleware

 OPC UA server/client: Standard way to expose PLC data to SCADA, historians, analytics.
Can run on the PLC CPU, a comms module, or an edge gateway/PC.

 Avanceon uses OPC UA a lot for: SCADA/Historian ingestion, inter-PLC data exchange
(when cross-vendor), and secure enterprise integration.

5) Gateways & protocol converters

What they do: Translate between protocols when devices don’t natively match your PLC.

 Examples: Modbus RTU ↔ Modbus TCP, Profibus ↔ Profinet, BACnet ↔ Modbus, IEC
61850 ↔ Modbus/OPC UA, HART ↔ Ethernet, etc.

 Why Avanceon uses them: To integrate mixed vendor equipment quickly without
changing field devices.

6) Network infrastructure (not PLC “modules” but essential)

 Industrial switches (managed preferred): VLANs, RSTP/MRP rings, diagnostics.

 Media converters: Copper↔fiber for long distances or EMI environments.

 Wireless: Wi-Fi/cellular radios for mobile HMIs or remote sites.

 Routers/NAT/Firewalls: Segmentation between control, BMS, and corporate networks.

In Schneider lists you’ll see Ethernet Infrastructure Modules, Switch, Fiber Converter, Wi-Fi—
these are infrastructure components, not PLC plug-in cards.
Decoding the terms you mentioned (module vs feature vs protocol)

Term you saw What it is Avanceon explanation

Hardware Ethernet ports for PLC; runs features like

Ethernet Control Modules
module scanning, device comms.

PLC/NOC cyclically reads/writes Modbus TCP

I/O Scanning Feature
devices like they’re I/O. Great for meters/VFDs.

Routes traffic between subnets (e.g., PLC

IP Forwarding Feature network ↔ device subnet). Use carefully with
IT.

For relays/substations; needs 61850-capable

IEC 61850 Protocol suite
PLC stack or a gateway.

Standard Expose PLC data to SCADA/IT securely; can be

OPC UA
interface on CPU, module, or gateway.

Publish/subscribe data sharing between PLCs

Global Data Feature
over Ethernet (fast controller-to-controller).

Ethernet Infrastructure
Switches, media converters, radios—build the
Modules / Switch / Fiber Infrastructure
network fabric.
Converter / Wi-Fi

Hardware Serial/fieldbus masters (Modbus RTU, Profibus,

Fieldbus Modules
modules CANopen, AS-i).

Motion/drives/I-O on CAN; needs CANopen

CANopen Protocol
module.

Remote Terminal Unit (a small PLC for remote

RTU Device class
sites). Not a module.

Modbus RTU/ASCII on RS-485; needs serial card

Modbus Serial Protocol
or gateway.

Fast fieldbus for drives/remote I/O; needs

Profibus-DP Protocol
Profibus master module.

EthWAY / EthWay Legacy protocol Older Schneider/Telemecanique Ethernet;

Term you saw What it is Avanceon explanation

usually via gateways in brownfield.

Schneider motor starters; often integrated via

TeSys U Device family Modbus or AS-i—needs matching
module/gateway.

Simple sensor/actuator bus; needs AS-i master

ASI (AS-Interface) Protocol
module/gateway.

Could mean multi-protocol or general-purpose

Universal Generic label
serial/Ethernet modules; check the datasheet.

Quick selection guide (how Avanceon typically chooses)

1. List every device & its native protocol

(VFDs/meters: Modbus TCP/RTU; Siemens I/O: PROFINET/Profibus; relays: IEC 61850;
BMS: BACnet/IP)

2. Prefer Ethernet first

Faster, easier diagnostics, structured networks. Use Modbus TCP / PROFINET /
EtherNet/IP / BACnet/IP where possible.

3. Use serial/fieldbus when required

Legacy devices or long RS-485 runs → Modbus RTU; older MCCs → Profibus; simple I/O
islands → AS-i.

4. Bridge with gateways when protocols don’t match

Saves cost/time versus replacing devices.

5. Plan network architecture

o Managed industrial switches, rings (RSTP/MRP) for resilience.

o Fiber for distance/EMI.

o VLANs / NAT between machine, BMS, and corporate.

o Time sync (NTP/PTP) for events, especially IEC 61850/DNP3.

6. SCADA & enterprise layer

Use OPC UA (and sometimes MQTT) for clean, secure data to SCADA/Historian/cloud.
Typical Avanceon patterns by application

 Central Cooling Plants / HVAC

PLC Ethernet module → Modbus TCP to chillers/VFDs/meters; BACnet/IP to BMS; OPC
UA to SCADA. Serial Modbus RTU if chillers are legacy.

 Water/Wastewater & Utilities

PLC/RTU with DNP3 (to master) or Modbus (to instruments); radio/cellular backhaul;
OPC UA to SCADA. Fiber rings at plants.

 Power & Substations

IEC 61850 (MMS/GOOSE) to relays; sometimes gateway to PLC/SCADA; precise time sync
(PTP). Separate protection vs control networks.

 Factory/MCCs
PROFINET or EtherNet/IP for I/O and drives; legacy Profibus to older MCC buckets;
Modbus TCP to meters.

Pros & cons cheat-sheet

 Ethernet (Modbus TCP/Profinet/EtherNet-IP/BACnet/IP):

o High speed, diagnostics, flexible topology

− Requires managed switches, IP planning, cybersecurity

 Modbus RTU (Serial):

o Low cost, easy wiring over long runs

− Shared bandwidth, polling delays, sensitive to wiring/termination

 Profibus-DP / CANopen / AS-i:

o Deterministic, proven in industry

− Legacy/limited tools; vendor-specific hardware

 IEC 61850:

o Native to modern relays; fast GOOSE messaging

− Specialist skills; strict time sync & engineering

 OPC UA:

o Cross-vendor, secure, structured info models

− Needs server configuration and certificate handling
Practical tips

 Keep one protocol per segment when possible (simpler troubleshooting).

 For RS-485, mind termination, biasing, and node count.

 On Ethernet, standardize IP plan, VLANs, DHCP reservations, and device naming.

 Enable diagnostics (device status, alarms) and time sync from day one.

 Document topologies (star/ring), cable types, and device roles in the handover pack.